Damodhar Ce ment Works

ExcellenceExcellence Through TeamworkThrough Teamwork

Water conservation through Water conservation through recycle and reuserecycle and reuse

Presented ByPresented By

ACC LimitedACC LimitedDamodhar Cement WorksDamodhar Cement Works

Damodhar Ce ment Works

Damodhar at a glance Damodhar at a glance ……..

•• DCSL commenced commercial production in October 1990 as a DCSL commenced commercial production in October 1990 as a joint venture project of WBIDC and Cement Corporation of India joint venture project of WBIDC and Cement Corporation of India LtdLtd

•• In September 1996 ACC Ltd. took over the management of the In September 1996 ACC Ltd. took over the management of the Company and it became a Subsidiary of the ACC Ltd. With Company and it became a Subsidiary of the ACC Ltd. With WBIDC as a partnerWBIDC as a partner

•• Capacity enhancement from 2.70 to 5.25 LTPA of Portland Slag Capacity enhancement from 2.70 to 5.25 LTPA of Portland Slag Cement in the year 1998 was taken up by ACCCement in the year 1998 was taken up by ACC

•• An ISO 9001 : 2000 and ISO 14001:2004 certified unitAn ISO 9001 : 2000 and ISO 14001:2004 certified unit

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Our Strategic VisionOur Strategic Vision

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Our Environmental Policy

Damodhar Ce ment Works

Cement Manufacturing ProcessCement Manufacturing Process

Ball Mill-2 16 T/H

Wet Slag sto rage at Ropeway Loading

Station

Ropeway 2.6 KM, Capacity 135 TPH

Bagging

RotoPacker

2 x 3800 T

Coal Mill

3 TPH

Coal Storag e

800 MT

Ball Mill-149 TPH

Slag Dryer

60TP H

Wagon Tippler 600 TPH

100 T Cap.2 nos

Ball Mill-3 15 TPH

Open Wet Slag Storag e

Capacity 35 KT

Covered storag e Hall

Clinker18000TDry Sl ag5000T

Gypsum8000T

Cement Sto rage SiloClinker

And Gypsum

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Drinking Water ConsumptionDrinking Water Consumption

Water consumption in Factory

166.25

242.36198.21 185.93

050

100150200250300

'04-'05 '05-'06 '06-'07 '07-'08

Year

Lit /

Pers

on /D

ay

Water Consumption in Colony

184

262.39196.48 200.22

050

100150200250300

'04-'05 '05-'06 '06-'07 '07-'08

Year

Lit /

Pers

on /D

ay

•2005-06 water con sumption high due to fly ash silo and cement silo

project

•2007-08 water con sumption high due to new construction of quarters

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Bench MarkingBench Marking

43.1

74

41.9

4

30.3

23

78.7

34

113.

009

93.2

33

91.9

62

156.

183

135.

173

40.7

91

122.

285

119.

526

0

20

40

60

80

100

120

140

160

180

'04-'05 '05 -'06 '06-'07 '07-'08Yea r

Cons

umpt

ion

(K m

3)

IndustrialDrinking/Domestic UseTotal

0.07

8

0.08

5

0.08

1

0.06

0.280.28 0.28

0.28

0.50.50.50.5

0

0.1

0.2

0.3

0.4

0.5

0.6

'04-'05 '05-'06 '06-'07 '07-'08

YearSp

ecifi

c W

ater

Co

nsum

ptio

n (m

3/T)

DCWNational BenchmarkInternational Benthmark

Damodhar Ce ment Works

Damodhar Riv er

Drinking WaterReserv oir

Process water Ta nk

Over Head Tank

Drinking Water

Process Water

Proc

ess

Wat

er Drinking Water

Water Flow Diagram

Plant Colony Village

Plant

FM FM

FM

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Sewage Treatment Plant

SWEAGE COLLECTION

SUMP

OXIDIZATION PLANT

CIRCULAR TANK

FILTER

SUPPLY FOR

IRRIGATION

BACK WASH

WATER TANK

TREATED WATER

RESERVOIR

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•• Applying Analog Applying Analog Flow Meter for Flow Meter for accuracyaccuracy

•• Maintain daily log Maintain daily log sheet to feed the sheet to feed the readingsreadings

•• Weekly report to Weekly report to Chief Manager Chief Manager Engg., Plant Engg., Plant operation head & operation head & Director PlantDirector Plant

Monitoring & Reporting SystemMonitoring & Reporting System

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The previous system of domestic waste water treatment having following demerits :

• The Domestic Waste water including the kitchen and washroom dischar ge is treated at sewage treatment plant

• After the plant expansion, filtration capacity of STP was not sufficient to take the increase of waste water day to day due to increase of population and quarters in colony

Idea Generation• Disconnection of Kitchen and bathroom line of A-Block &

Hutment buildings from main STP line • Waste water from kitchen and bathroom collect in a pond after

gravitation f iltration process and this water use for gardening and breeding fish

Project Project --1 : Reuse of Domestic Waste Water1 : Reuse of Domestic Waste Water

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Kitche n and Was hroom Water Collecte d into Pond

Plantation at Colony

Project Project -- 1 : Reuse of domestic waste water1 : Reuse of domestic waste water

Damodhar Ce ment Works

RESULTS :RESULTS :

––Recycling of waste Recycling of waste water and optimum water and optimum usage of resource usage of resource

––Smooth and efficient Smooth and efficient operation of STPoperation of STP

––Ensure ZERO dischargeEnsure ZERO discharge

0 0 0 0

600

'03-'04

'04-'05

'05-'06

'06-'07

'07-'08

YearV

olum

e (L

it.)

Dischargewater (KL)

Project Project -- 1 : Reuse of domestic waste water1 : Reuse of domestic waste water

Damodhar Ce ment Works

The previous water supply system (surface water from Damodar river) had the following demerits:

• Unhygienic water quality specially during monsoon.• During summer and winter, 10 nos. labor used daily for

channeling the water to the pumping point• 18 KW pumps used for lif ting the water and 7.5 KW pump

used for pressure f iltration• High treatment cost of Rs. 4000.00 per month

The Cost of production was Rs. 5.50 per KL.

Project Project –– 2 : Reduction of river water usage2 : Reduction of river water usage

Damodhar Ce ment Works

IDEA GENERATION :IDEA GENERATION :

•• Elimination of the surface water supply and associated Elimination of the surface water supply and associated filtration system by installation of a deep bore well filtration system by installation of a deep bore well pumping unit at middle of river bedpumping unit at middle of river bed

•• Drawing the subsoil water which is much more hygienic Drawing the subsoil water which is much more hygienic and available throughout the yearand available throughout the year

Project Project –– 2 : Reduction of river water usage2 : Reduction of river water usage

Damodhar Ce ment Works

Actions ImplementedActions Implementedü 40 feet deep bore well pump has been installed ü Water treatment plant operation has been stopped

Project Project –– 2 : Reduction of river water usage2 : Reduction of river water usage

Damodhar Ce ment Works

RESULTS:RESULTS:

•• Continuous supply of good quality drinking Continuous supply of good quality drinking water even in rainy season water even in rainy season

•• Operation and maintenance cost have been Operation and maintenance cost have been reduced to reduced to RsRs. 1.20 per KL. 1.20 per KL

•• Hence annual saving is Hence annual saving is RsRs. 2.40 . 2.40 LakhsLakhs

Project Project –– 2 : Reduction of river water usage2 : Reduction of river water usage

Damodhar Ce ment Works

Previous water supply system :

• Cooling water supplied to the machines was not recirculated and reused

• High water loss• High amount of water cess paid by the company

Idea Generation

All the return water lines have been connected to the main return water pipe.

Project Project –– 3 : Close circuiting of process water3 : Close circuiting of process water

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Result :

• Reduction if water consumption as well as discharge by 8%

• Reduction in pump house power consumption by 6%

Project Project –– 3 : Close circuiting of process water3 : Close circuiting of process water

Damodhar Ce ment Works

AwarenessAwareness

•• DCW sent representative to Delhi for training on Water DCW sent representative to Delhi for training on Water Management systemManagement system

•• Mass awareness of taking hygienic water through distribution of Mass awareness of taking hygienic water through distribution of leaflets & electronic media among the nearby community & leaflets & electronic media among the nearby community & colony inhabitants colony inhabitants

•• Providing hygienic water to the nearby v illagers Providing hygienic water to the nearby v illagers •• Periodic checking of quality of water by internal as well as Periodic checking of quality of water by internal as well as

exter nal authority exter nal authority •• Distribution of leaf lets for awareness towards water borne Distribution of leaf lets for awareness towards water borne

diseasesdiseases•• Arrange drawing competition on Arrange drawing competition on ‘‘Conservation Of Natural Conservation Of Natural

resour cesresour ces’’ among the colony & nearby inhabitantsamong the colony & nearby inhabitants’’ childrenchildren•• ‘‘Suggestion SchemeSuggestion Scheme’’ for new idea generationfor new idea generation•• Envir onmental Quiz Competition conducted by DCW clubEnvir onmental Quiz Competition conducted by DCW club

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Sustainable DevelopmentSustainable Development

•• Rain Water Harvesting: Constructed Rain Water Harvesting: Constructed earthen pond at Colony & concrete earthen pond at Colony & concrete reservoir inside plant reservoir inside plant

•• Use of Treated water from Sewage Use of Treated water from Sewage Treatment plant for plant & colony Treatment plant for plant & colony plantation & gardeningplantation & gardening

•• Reserve shower & kitchen water into Reserve shower & kitchen water into pond for plantation pond for plantation

•• Complete Looping of process water for Complete Looping of process water for recirculationrecirculation

•• Optimizing the water distribution Optimizing the water distribution cycle frequency towards colony & cycle frequency towards colony & near by inhabitantsnear by inhabitants

•• Installation of float valves to all the Installation of float valves to all the water reservoirs (tanks) at all the water reservoirs (tanks) at all the colony buildingscolony buildings

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Our Future PlanOur Future Plan…………....

•• Integration with OSHAS 18001Integration with OSHAS 18001•• Annual external audits through authorized auditing Annual external audits through authorized auditing

agenciesagencies•• Involvement of people through small group activitiesInvolvement of people through small group activities•• Developing InDeveloping In--house expertise for auditshouse expertise for audits•• Installation of flow meter at consumption points for Installation of flow meter at consumption points for

better monitoringbetter monitoring•• Zero water leakageZero water leakage•• Arrangements for collecting storm water from roof Arrangements for collecting storm water from roof

shed and collecting in the earthen pondsshed and collecting in the earthen ponds

Damodhar Ce ment Works

We can do no great things ; We can do no great things ; only small things with great love.only small things with great love.

-- Mother TeresaMother Teresa

Damodhar Ce ment Works